Leadframe Support Bracket for Wire Spacing Stability
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Solution Overview
Problem
During the overmolding process of circuit boards, the force of the mold material can cause wires connecting dies to deform, leading to potential electrical arcing due to insufficient spacing, which is not effectively addressed by existing technologies.
Innovation Solution
A support bracket is integrated between die pads in the leadframe, featuring a planar surface that maintains the wires at a predetermined distance from the dies, providing upward reaction force and frictional resistance to prevent deformation and arcing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are allowed to extend freely between dies during overmolding, then manufacturing simplicity is maintained, but wire deformation and electrical arcing occur due to insufficient spacing
Solution Approach 1:
A support bracket is introduced as an intermediary component between the dies and the wire. The bracket includes a support surface positioned at a predetermined distance from the die pad, which physically supports the wire during overmolding to maintain proper spacing and prevent deformation and electrical arcing.
Solution Approach 2:
The support bracket is pre-positioned on the leadframe before the wire is attached and before the overmolding process occurs. The bracket is configured in advance to provide support at the correct height and location, ensuring the wire maintains proper spacing throughout the subsequent manufacturing steps.
2Reliability
If wire spacing is increased to prevent arcing, then electrical safety is improved, but manufacturing precision requirements increase
Solution Approach 1:
The support bracket serves as a mechanical intermediary that physically enforces the required spacing between the wire and the die pad. By providing a support surface at a predetermined distance from the die pad, the bracket ensures adequate spacing is maintained without requiring high precision in wire placement or tension control during manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The support bracket effectively prevents wire sagging and sweeping, ensuring the wires remain at a safe height during overmolding, thereby preventing electrical arcing and reducing the need for costly x-ray inspections, while optimizing manufacturing efficiency.
Implementation Method 1
providing upward reaction force and frictional resistance to prevent deformation and arcing
Data Source
AI summary
A leadframe includes a plurality of interconnected support members. A pair of die pads is connected to the support members and configured to receive a pair of dies electrically connected by at least one wire. A support bracket extends between the die pads and includes a surface for maintaining the at least one wire at a predetermined distance from the die pads during overmolding of the leadframe.